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Shay's General Kenobi W.I.P
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Shay Kenobi ()
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PostPosted: Fri Apr 25, 2014 12:48 am    Post subject: Reply with quote

Thanks very much Al, I'm glad you like it so far Very Happy

That's a good idea Nick, I am going off to put it to the test now. I appreciate the help thanks mate. Thumbs up
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Ixam Let'si ()
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PostPosted: Fri Apr 25, 2014 4:28 am    Post subject: Reply with quote

I really can't wait to see the pics of the weathering and whether Nicks suggestions proved successful.
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Shay Kenobi ()
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PostPosted: Mon Apr 28, 2014 9:52 am    Post subject: Reply with quote

Shoulder Bells.


These are quite different to clone bells and I wasnít quite sure how to do them. None of the usual armour producers make them so I guess I will have to do them my self.
I was walking through my local hardware one day and I saw these things..






They are just knee pads for tilers or tradesmen. I removed the elastic straps. I thought they had a nice padded thickness to them and perhaps they would work.





I thought, if I can just modify the shape a little by cutting out this section here, they are about the right size Ė they may work ??


The surface was a little dimpled and would have to be sanded out and obviously painted white.


I came to my senses in the end and thought I needed to do a better job but I do think you could actually use these and get them to look pretty good. I thought it was a bridge too far but someone with better skills could be successful Iím certain.

I went back to the drawing board with trying to mould my own shape out of ABS.

I looked around for something that had the same shape as the armour that I could use as a mould.

I know it has been done before so I looked at the various footballs.
The Aussie balls are just slightly more elongated then the NFL balls and the NFL balls seemed to be a closer shape to the shoulder bells.

With apologies to Tony Romo ( Go Cowboys ! ) Ö. Very Happy Very Happy



I tried heating a sheet of ABS in a friends large industrial oven and simply draping it over the ball when hot and smoothing around the shape by hand ( Gloves )Ö

Now I told you that I was going to share every part of this project with you, even the screw ups Ė itís all learning and may help someone else BUTÖ. Even I was too traumatised by the result to snap off some pictures
IT WAS UGLY. Laughing Laughing Laughing


It was not even close and never going to work. I knew I would have to talk to the professionals.

I found a company nearby that specialised in Vac forming. Well , I thought my troubles were over Ė this is EXACTLY what is needed. Just hand him the football and he can put it in the vac forming thingymy jig and I will have some shoulder bells.


Actually no. Rolling Eyes


He explained to me that the mould has to be something solid that can have holes drilled through so when the suction is applied, it will suck the ABS down unto the shape to give an exact copy. He told me that I needed a mould of the football ( or actually half the football ) and that creating a mould was very expensive.


I tried covering it with moulding clay but it was never going to be strong enough. In the end, I approached an old local wood craftsman. I took him the ball and explained that I needed this shape only cut in half ( around its equator ) in wood.


After 2 days he handed me this beautiful , incredible carving.











I took it back to the vac form guy and he pumped out some shoulder bells.

Itís quite a thick ABS I think about 5mm. We cut the end that we didnít need off and it looks like thisÖ





They turned out great. What is interesting and what you canít really see in the picture, is that the grain of the wood was transferred into the ABS. Apparently the wood swells and expands under the heat.

I just had to spend a lot of time sanding to take it dead smooth.

I modified the shape very slightly and took the corners off to a rounded finish with a grinder to look like this..







I painted them using the same process described earlier in the build.
This is how the gloss looks before you knock it back a bit.






Not sure if itís clear enough but the shoulder bell hasnít been sanded back in soapy water. The leg armour has. Itís just to take the gloss back a little.

So this is what they look like ď finished ďÖ




Iíll show the Jedi symbol and weathering tomorrow.
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Anakin Skywalker ()
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PostPosted: Mon Apr 28, 2014 11:54 am    Post subject: Reply with quote

Beautiful shoulderbells!
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Ixam Let'si ()
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PostPosted: Mon Apr 28, 2014 12:02 pm    Post subject: Reply with quote

They look great Shay.
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jedimastermolina (Alan)
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PostPosted: Wed Apr 30, 2014 10:31 am    Post subject: Reply with quote

now that you have the mold you can provide us with shoulder bells Smile
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Shay Kenobi ()
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PostPosted: Thu May 01, 2014 9:40 am    Post subject: Reply with quote

Jedimastermolina wrote :

"now that you have the mold you can provide us with shoulder bells"



Hi Alan. Unfortunately the original wooden mould was damaged by the heat. I think I could still get some done using the originals however ? But I did get a couple of extra sets made just as back ups. If you need a set let me know and Iím sure I could help out. Thumbs up



Anakin Skywalker wrote :
Beautiful shoulderbells!

Hello Anakin. Thank you for that. In that case, I hope you like what I am about to show you Very Happy


Ixam Let'si wrote :

"They look great Shay."


This is for you Max. You keep asking about the weathering , well this is what it came out like. Wink




Just quickly, this is what I meant when I said that Obiís shoulder bells are very close to Clone bells only upside downÖ



This sits perfectly on my shoulder but is the wrong way around. Similar to the Cloneís look ( sorry about the white on white, just quickly snapped a photo to show you what I was talking about )




I started off just practicing on another shoulder bell I made to see how the Jedi symbol would come out. I think you may have been asking about this in another thread Rog but all I did is take the artwork off the internet to a signage place and had them print a vinyl sticker.



Then I masked up the rest of the bell..




Here is what I learned from this stage of the build.

Putting a flat transfer on to a curved surface is harder than it looks! It doesnít go on perfectly and you have to carefully slice little cuts to negotiate the curves but itís no biggy and in the end you can get it such that no one would notice the corrections made.





When I took the sticker of the backing sheet, it became like a sticky little spider with its elements sticking to each other and in all the wrong spots. It was only later when I was talking to the signage guy about how tuff it was to get right that he said OMG I forgot to give you the application tape !! LOL Laughing This makes it a lot easier, holding everything in place while you get it just where you want it. The other pearl of wisdom the signage guy passed on AFTER I had applied it was that if you mist the surface with a spray bottle of water and a single drop of washing up liquid, you can slide the image around somewhat to get it in the exact position. Oh well, good to know for next time Wink



Ok, sprayed the practice BellÖ.





Just a practice but I think it looks OK and should work.





I have to start this next bit with a big thank you. No matter how hard I tried, I just couldnít get the kind of finish and weathering effects that I was looking for with a simple spray can.

Adam S. from our base introduced me to Stacy, a friend of his who is extremely talented with an air gun. I canít thank you enough Adam it was exactly what I was hoping for. bow



Stacy and I spent probably ten hours discussing reference shots, comparing colours and looking at different effects. The painting was rubbed back and started again 3 times until we were happy. I think the final look was worth it.

















This is how the foaming or 3D Ďing of the armour will look. This hasnít been attached, I have only inserted the foam to give you an idea. It will look better as I have to knock back the grey around the edge of the ABS and weather the foam a little so it colour matches a bit closer and looks like it is all one piece. Well, thatís what Iím hoping for anyway Laughing



Believe it or not, the Rebel symbol Bell isnít my favourite itís actually this one, I really love the detail.





















So anyway, still lots to work on but hope you all think itís going well so far.
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Obickay ()
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PostPosted: Thu May 01, 2014 10:41 am    Post subject: Reply with quote

Man that is beautiful.
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Adam.S ()
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PostPosted: Thu May 01, 2014 10:50 am    Post subject: Reply with quote

Ha ha I told you you would be happy , luckily he is my best mate and my best man at my Wedding or we wouldn't be mates after you too finish this lol.
He painted my Rex so I knew you would be in good Hands.
Loving it.
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jedimastermolina (Alan)
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PostPosted: Thu May 01, 2014 11:20 am    Post subject: Reply with quote

Amazing mate amazing
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Anakin Skywalker ()
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PostPosted: Thu May 01, 2014 12:39 pm    Post subject: Reply with quote

............ Shocked


















on a side note that 3d-ing is a great idea
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Shay Kenobi ()
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PostPosted: Thu May 01, 2014 1:01 pm    Post subject: Reply with quote

Those are nice comments, thanks guys Very Happy

Anakin I thought yours was an angry face at first and you were telling me you didn't like it LOL. I hope that's shocked in a good way Laughing
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PostPosted: Thu May 01, 2014 1:18 pm    Post subject: Reply with quote

It was: I am in awe face Wink
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Shay Kenobi ()
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PostPosted: Thu May 01, 2014 1:23 pm    Post subject: Reply with quote

Hahahaha . I'm relieved Very Happy
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davej ()
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PostPosted: Thu May 01, 2014 2:04 pm    Post subject: Reply with quote

Shane, great work!!
I remember a day, not that long ago, when we were standing in Engadine Pub car park, and you were saying that you would need to get someone to do all of this for you.
Seems that you are doing a mighty fine job, all by yourself!!
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